Knife for manufacturing vein pattern of artificial marble, method for manufacturing artificial marble using same, and artificial marble

Abstract

The present invention relates to artificial marble comprising: a base part; and a pattern part, wherein the pattern part includes at least one of a first pattern and a second pattern, wherein the first pattern includes a first vein and a second vein that have a difference in brightness values (L) calculated with CIE color coordinates of 4 or more, and wherein the second pattern includes a vein including two or more consecutive portions, and the difference in brightness values (L) calculated with CIE color coordinates of the two or more consecutive portions being 4 or more.

Description

Knife for manufacturing vein patterns of artificial marble, method for manufacturing artificial marble using the same, and artificial marble

[0001] This application claims the benefit of the filing dates of Korean Patent Application No. 10-2023-0188645, filed with the Korean Intellectual Property Office on December 21, 2023, Korean Patent Application No. 10-2023-0188596, filed with the Korean Intellectual Property Office on December 21, 2023, Korean Patent Application No. 10-2024-0026481, filed with the Korean Intellectual Property Office on February 23, 2024, and Korean Patent Application No. 10-2024-0026467, filed with the Korean Intellectual Property Office on February 23, 2024, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to a knife for manufacturing a vein pattern of artificial marble, a method for manufacturing artificial marble using the same, and artificial marble.

[0003] Engineered stone, also known as Easton, is an artificial marble used as an interior decoration material with a texture and feel similar to natural stone. Research has been conducted in the industry to enhance the aesthetics of artificial marble by improving its color and appearance. For example, Korean Patent No. 10-1270415 discloses an artificial marble with a variety of patterns and appearances using marble chips. Demand for engineered stone is steadily increasing for indoor flooring, wall decoration, and kitchen countertops, with products primarily imitating natural stone species such as granite and marble.

[0004] However, in the recent interior design market, interest in natural stones such as quartzite with more luxurious patterns is gradually increasing.

[0005] In addition, conventional artificial marble uses a robot-based spraying method to create patterns, and because it uses one color or at most two colors, there are limitations in expressing the color difference and brightness of the veins in various ways.

[0006] To overcome these limitations and reflect these trends, the Easton industry is making great efforts to implement natural stone.

[0007] The present invention provides a knife for manufacturing vein patterns of artificial marble and a method for manufacturing artificial marble using the same. More specifically, the present invention provides a knife for manufacturing vein patterns of artificial marble capable of realizing color differences in veins of various natural stones and a method for manufacturing artificial marble using the same.

[0008] Furthermore, the present invention seeks to provide artificial marble that embodies the color differences of natural stone. More specifically, the present invention seeks to provide artificial marble that embodies various patterns of natural stone.

[0009] One embodiment of the present invention provides an artificial marble comprising a base portion and a pattern portion, wherein the pattern portion comprises at least one of a first pattern and a second pattern, wherein the first pattern comprises a first vane and a second vane having a difference in brightness (L) calculated by CIE color coordinates of 4 or more, and wherein the second pattern comprises a vane including two or more consecutive portions, and wherein the difference in brightness (L) calculated by CIE color coordinates of the two or more consecutive portions is 4 or more.

[0010] One embodiment of the present invention provides a knife for manufacturing a vein pattern, comprising an emboss plate having a first inclined surface and a second inclined surface facing each other based on a moving direction of the knife, wherein the knife includes at least two of the emboss plates, at least two of the emboss plates have different widths, and the width of the emboss plate is the maximum distance between the first inclined surface and the second inclined surface.

[0011] One embodiment of the present invention provides a method for manufacturing artificial marble, including a base layer forming step of forming a base layer in a plate shape by dispensing a base composition onto a horizontally oriented mold; a pattern forming step of forming an intaglio pattern on the base layer using a knife for manufacturing the vein pattern; a vein injecting step of injecting a vein pattern composition into the intaglio pattern; and an artificial marble forming step of forming an artificial marble having a vein pattern by performing a compression process and a heat treatment process.

[0012] According to one embodiment of the present invention, a plurality of veins having different brightness or saturation are positioned spaced apart from each other or are continuous in a single, uninterrupted pattern to implement a natural gradation effect in artificial marble.

[0013] According to one embodiment of the present invention, a knife for manufacturing a vein pattern of artificial marble includes two or more embossing plates having different widths, so that one uninterrupted vein pattern can include two or more areas having different sharpness.

[0014] In addition, according to one embodiment of the present invention, a natural gradation effect of a vein pattern can be implemented by adjusting the sharpness according to the position of one vein pattern.

[0015] FIG. 1(a) is a drawing showing a pattern portion including a first pattern according to one embodiment of the present invention, FIG. 1(b) is a drawing showing a pattern portion including a second pattern according to one embodiment of the present invention, and FIG. 1(c) is a drawing showing a pattern portion including a contact point by intersecting a first vane and a second vane of the first pattern according to one embodiment of the present invention.

[0016] FIG. 2(a) is a perspective view showing a knife according to one embodiment of the present invention, FIG. 2(b) is a cross-sectional view taken along line A-A' of FIG. 2(a), and FIG. 2(c) is a cross-sectional view taken along line B-B' of FIG. 2(a).

[0017] Figure 3 is a perspective view showing a knife according to another embodiment of the present invention.

[0018] FIG. 4(a) is a perspective view showing a knife according to another embodiment of the present invention, FIG. 4(b) is a cross-sectional view taken along line A-A' of FIG. 4(a), and FIG. 4(c) is a cross-sectional view taken along line B-B' of FIG. 3(a).

[0019] Figure 5 is a perspective view showing a knife according to another embodiment of the present invention.

[0020] Figure 6 is a perspective view showing a knife according to another embodiment of the present invention.

[0021] Fig. 7(a) is a perspective view showing a knife according to another embodiment of the present invention, and Fig. 7(b) is a cross-sectional view taken along line A-A' of Fig. 7(a).

[0022] Fig. 8 is a photograph illustrating the shape of a knife having an emboss plate crosswise according to the present invention.

[0023] Figure 9 is a flowchart illustrating a method for manufacturing artificial marble according to one embodiment of the present invention.

[0024] [Explanation of symbols]

[0025] 1: Knife for making veins

[0026] 100, 100a, 100b, 100c: Embossed plates

[0027] 110, 110a, 110b: First slope

[0028] 120, 120a, 120b: Second slope

[0029] 10: Base layer

[0030] 20: Vein pattern

[0031] B: Bass section

[0032] P2', P2”: Second pattern

[0033] V1, V1', V1”: 1st vane

[0034] V2, V2', V2”: Second vane

[0035] V3”: Third Bane

[0036] This detailed description of the present invention is intended to fully explain the present invention to those skilled in the art. Throughout the specification, whenever a part is referred to as "comprising" a certain component or "characterizing" a certain structure or shape, unless specifically stated otherwise, this does not exclude other components or structures or shapes, but rather implies the inclusion of other components, structures, and shapes.

[0037] The present invention is susceptible to various modifications and embodiments. Therefore, specific embodiments are presented and described in detail in the detailed description. However, this is not intended to limit the scope of the invention to these embodiments, and it should be understood that all modifications, equivalents, and alternatives fall within the spirit and technical scope of the present invention.

[0038] Hereinafter, the present invention will be described in detail with reference to the drawings. However, the drawings are intended to illustrate the present invention, and the scope of the present invention is not limited by the drawings.

[0039]

[0040] The artificial marble according to the present invention includes a base portion (B) and a pattern portion.

[0041] The L*, a*, and b* values ​​of the CIE color coordinates of the pattern section are obtained by scanning the artificial marble with a Konica Minolta bizhub c368 scanner at a resolution of 600 dpi. Then, the image of the artificial marble scanned through the scanner is imported into Photoshop, and the CIE color coordinate values ​​for each vein or each area of ​​the vein are measured.

[0042] For example, multiple arbitrary areas are designated to measure L*, a*, and b* values ​​according to CIE color coordinates, and the brightness value (L), saturation value (C), and color difference (△E) described later can be derived as the average value of the L*, a*, and b* values ​​of the multiple areas.

[0043] Alternatively, the brightness value (L), saturation value (C), and color difference (△E) can be derived as the average of the remaining values ​​excluding the highest and lowest values ​​of L*, a*, and b* values ​​among multiple areas.

[0044] Color coordinates are coordinates in the CIE color space, which are color difference values ​​specified by the International Commission on Illumination (CIE, Commossion International de l'Eclairage), and any arbitrary location in the CIE color space can be expressed with three coordinate values: L*, a*, and b*.

[0045] The above L* value represents brightness. If L* is 0, it is black, and if L* is 100, it is white. The above a* value indicates whether the color with the corresponding color coordinates leans toward pure magenta or pure green, and the above b* value indicates whether the color with the corresponding color coordinates leans toward pure yellow or pure blue.

[0046] The above a* value ranges from -a to +a, and the maximum a* value (a* max) represents pure magenta, and the minimum a* value (a* min) represents pure green. A negative a* value indicates a color difference biased toward green, and a positive a* value indicates a color difference biased toward red. For example, when comparing a*=80 and a*=50, a*=80 is closer to pure red than a*=50.

[0047] The above b* value ranges from -b to +b. The maximum value of b* (b* max) represents pure yellow, and the minimum value of b* (b* min) represents pure blue. A negative b* value indicates a color difference biased toward pure blue, and a positive b* value indicates a color difference biased toward pure yellow. For example, when comparing b*=80 and b*=20, b*=80 is closer to pure yellow than b*=20.

[0048] The above pattern portion may include at least one of the first pattern and the second pattern.

[0049] Referring to Fig. 1(a), the pattern portion includes a first pattern, and the first pattern includes a first vane (V1) and a second vane (V2) having a brightness value difference of 4 or more. Preferably, the brightness value difference between the first vane (V1) and the second vane (V2) may be 4 to 15. More preferably, it may be 5 to 10.

[0050] The artificial marble according to Fig. 1 includes two veins, but the present invention is not limited thereto, and may include multiple veins in which at least one of brightness value, saturation value, and color difference is different from each other.

[0051] At this time, the saturation (C*ab or x) value is calculated using the formula (a) as the CIE color coordinate value. 2 +b 2 ) 1 / 2 can be calculated as follows. And, the color difference (ΔE) is calculated using the CIE color coordinate value as the formula (ΔL 2 +Δa 2 +Δb 2 ) 1 / 2 can be calculated as

[0052] The first vane (V1) and the second vane (V2) may be positioned at least partially separated from each other. For example, the first vane (V1) and the second vane (V2) may have one end in contact and the separation distance may increase in the longitudinal direction of the first vane (V1) and the second vane (V2). Alternatively, the first vane (V1) and the second vane (V2) may be positioned without contact and spaced apart from one end to the other by the same or different distances.

[0053] The ratio of the brightness values ​​of the first vane (V1) and the second vane (V2) (L v1 / L v2 or L v2 / L v1 ) may be less than or equal to 0.95. At this time, the brightness value ratio is a value obtained by dividing the larger value by the smaller value between the brightness value of the first vane (V1) and the brightness value of the second vane (V2).

[0054] The difference in saturation values ​​may vary depending on the color of the first pattern. In one embodiment, when the first pattern is gold, the difference in saturation values ​​between the first vein (V1) and the second vein (V2) may be 10 to 18.

[0055] In another embodiment, when the first pattern is gray, the difference in saturation between the first vane (V1) and the second vane (V2) may be 1 to 3.

[0056] The saturation ratio (C) of the first vane (V1) and the second vane (V2) V1 / C V2 or C V2 / C V1 ) may be less than 0.7. The saturation value ratio of the first vane (V1) and the second vane (V2) according to one embodiment may be less than 0.5, and the saturation value ratio of the first vane (V1) and the second vane (V2) according to another embodiment may be more than 0.4 and less than 0.7.

[0057] The color difference (△E) between the first vane (V1) and the second vane (V2) may be greater than 3. Preferably, the color difference between the first vane (V1) and the second vane (V2) may be 9 to 20, and more preferably, 9 to 17.

[0058] If the color difference between the first vane (V1) and the second vane (V2) satisfies the above range, the color difference between the first vane (V1) and the second vane (V2) can be visually confirmed. In other words, if the color difference between the first vane (V1) and the second vane (V2) is 3 or less, a problem occurs in which the color difference between the first vane (V1) and the second vane (V2) cannot be visually confirmed.

[0059] By ensuring that at least one of the brightness values, saturation values, and color differences of multiple veins included in the artificial marble satisfies the above range, a pattern having various brightness values, saturation values, and color differences is included in one artificial marble, and thus, an aesthetic feel more similar to that of natural stone can be provided.

[0060] The second pattern may include two or more consecutive portions having a difference in brightness of 4 or more. Preferably, the difference in brightness of the two or more consecutive portions may be 4 to 15. More preferably, it may be 5 to 10.

[0061] At this time, the fact that two or more parts of the vane are continuous means that the width or width of two or more parts is 0.5 mm or more. In other words, if there is a part of the vane whose width or width is less than 0.5 mm, the vane is not continuous.

[0062] For example, referring to Fig. 1(b), the artificial marble includes a plurality of the second patterns. The second patterns include two consecutive portions whose brightness values ​​calculated using CIE color coordinate values ​​satisfy the above range, and the two portions are each a first vane (V1) and a second vane (V2) of the second pattern.

[0063] One (P2') of the plurality of second patterns (P2', P2”) includes a first vane (V1') and a second vane (V2') in which at least one of a brightness value, a saturation value, and a color difference calculated using CIE color coordinate values ​​is different from each other.

[0064] Another second pattern (P2”) includes a first vane (V1”), a second vane (V2”), and a third vane (V3”), each of which has different values ​​for brightness, saturation, and color difference calculated using CIE color coordinates.

[0065] And, the ratio of brightness values ​​of two or more consecutive parts (L min / L max ) may be less than 0.95.

[0066] The difference in saturation values ​​may vary depending on the color of the second pattern. In one embodiment, when the second pattern is gold, the difference in saturation values ​​of two or more consecutive portions may be 10 to 18.

[0067] In another embodiment, when the second pattern is gray, the difference in saturation values ​​of two or more consecutive portions may be 1 to 3.

[0068] The saturation ratio of two or more consecutive parts (C min / C max ) may be less than 0.7. The saturation value ratio of two or more consecutive portions according to one embodiment may be less than 0.5, and the saturation value ratio of two or more consecutive portions according to another embodiment may be greater than 0.4 and less than 0.7.

[0069] The color difference (△E) of two or more consecutive parts may be greater than 3. Preferably, the color difference of two or more consecutive parts may be 9 to 20, and more preferably, 9 to 17.

[0070] And, the brightness value of the vein included in the pattern portion may be 80 or higher. Preferably, the brightness value of the vein may be 82 or higher, and more preferably, 84 or higher.

[0071] The brightness value of the vein included in the pattern portion may be 95 or less. Preferably, the brightness value of the vein may be 90 or less, and more preferably, 88 or less.

[0072] And, the saturation value of the vein included in the pattern portion may be 25 or less. Preferably, the saturation value of the vein may be 20 or less, and more preferably, 18 or less.

[0073] The saturation value of the vein included in the pattern portion may be 1 or greater. Preferably, the saturation value of the vein may be 2 or greater, and more preferably, 3 or greater.

[0074] Since the vein area of ​​the second pattern satisfies the difference in brightness or saturation, the difference in brightness or saturation between the plurality of areas included in the vein is clearly expressed, and thus, the pattern included in the artificial marble can be naturally implemented.

[0075] The second pattern may have a gradient boundary between two or more consecutive portions of the vein having different brightness or saturation values. Specifically, the two or more consecutive portions of the second pattern may be provided such that the veins are connected in the length direction or width direction.

[0076] At this time, among two or more consecutive portions, adjacent portions may have at least one of a brightness value and a saturation value that are different from each other. In addition, the boundary portion may have a gradient area in which the brightness value or the saturation value gradually increases or decreases.

[0077] For example, a second pattern includes a single vein and a first portion and a second portion having different brightness values. The vein may be connected along its length by a first portion having a brightness value of 88 and a second portion having a brightness value of 84. In this case, the boundary where the first portion and the second portion meet may have a brightness value that gradually increases from 84 to 88 or gradually decreases from 88 to 84.

[0078] The artificial marble according to the present invention can naturally connect adjacent veins having different brightness or saturation values ​​by a boundary area or a gradient area.

[0079] The first pattern and the second pattern according to the present invention may each independently include two or more vanes having a total length of 5 cm or more. Preferably, the first pattern and the second pattern may each independently include three or more vanes having a total length of 5 cm or more. In this case, the total length refers to the distance from one end to the other end in the longitudinal direction of one of the vanes of the first pattern and the second pattern.

[0080] Since the first pattern and the second pattern according to the present invention include two or more veins, the pattern portion included in the artificial marble can implement various brightness values ​​and saturation values, thereby implementing the unique texture of a material such as natural stone in a variety of ways.

[0081] The area including the vein of the above artificial marble may have a combat success rate of 6.0% to 20.0% when measuring the combat success rate using a turbidimeter (NDH 5000 of Nippon Denshoku) for a sample of the area including the vein of the artificial marble having a width of 2 cm, a length of 2 cm, and a thickness of 1.5 cm.

[0082] The vane according to the present invention may have a straight pattern, a curved pattern, or a combination thereof.

[0083] Here, a straight line pattern refers to a pattern in which a straight line is connected without a break from one end of the vane to the other. In other words, a straight line pattern may be a form in which one or more straight lines are connected without a break from one end of the vane to the other. Therefore, when multiple straight lines are connected, a certain angle can be formed.

[0084] And, the veins can intersect with each other. In one embodiment, a plurality of straight patterns can intersect with each other, a plurality of curved patterns can intersect with each other, or a straight pattern and a curved pattern can intersect with each other.

[0085] For example, when multiple straight line patterns intersect each other, they can be formed in the shape of Y, X, etc.

[0086] Referring to Fig. 1(c), the pattern portion may include a plurality of first patterns. In addition, the first vane and the second vane of the first pattern may intersect each other and include at least one contact point.

[0087] And, the angle formed by the contact point and the first and second vanes may be 30° or more. Preferably, the angle formed by the contact point and the first and second vanes may be 40° or more, and more preferably, it may be 40° to 90°.

[0088] If the angle formed by the first and second vanes of the first pattern satisfies the above-mentioned angle range, the pattern can be clearly displayed even at the point of contact where the first and second vanes intersect. In other words, if the angle formed by the first and second vanes exceeds the above-mentioned angle range, the pattern at the point of contact may become blurred and unclear.

[0089] The first pattern may have a minimum distance between the first vane and the second vane of less than 80 mm. Preferably, the minimum distance between the first vane and the second vane may be less than 60 mm, and more preferably, less than 40 mm.

[0090] In the case where conventional artificial marble includes a distance of less than 80 mm between adjacent negative patterns among multiple negative patterns, when a vein pattern composition is sprayed on one negative pattern, a problem occurs in which the vein pattern composition is also sprayed on another adjacent negative pattern.

[0091] That is, depending on the spraying distance of the device spraying the vein pattern composition, if the distance between the plurality of negative patterns of conventional artificial marble is close, it is not easy to inject the vein pattern composition having different brightness values, saturation values, and color differences into each of the negative patterns with adjacent spacing distances.

[0092] However, the pattern portion according to the present invention has the effect of controlling the brightness value and the saturation value regardless of the distance between the first and second vanes and the vane pattern composition by controlling at least one of the brightness value, the saturation value and the color difference by the thickness or width deviation of the knife and the embossing plate for manufacturing the vane pattern forming the first and second vanes.

[0093] In addition, the first pattern may be such that the minimum separation distance between adjacent first and second vanes is less than 80 mm, preferably less than 60 mm, and more preferably less than 40 mm, even when the first and second vanes do not intersect.

[0094] In another embodiment, the pattern portion may include a plurality of second patterns, and the plurality of second patterns may intersect each other and include at least one contact point.

[0095] And, the angle formed by the contact point and the two second patterns adjacent to the contact point may be 30° or more. Preferably, the angle formed by the contact point and the two second patterns may be 40° or more, and more preferably, it may be 40° to 90°.

[0096] The minimum distance between two adjacent second patterns forming a contact point may be less than 80 mm. Preferably, the minimum distance between two second patterns may be less than 60 mm, and more preferably, it may be less than 40 mm.

[0097] The pattern portion according to the present invention may include both the first pattern and the second pattern. For example, the pattern portion may each include a plurality of first patterns and a plurality of second patterns. Alternatively, the pattern portion may include a contact point where the first pattern and the second pattern intersect each other. In other words, the first vane and the second vane may not intersect, and the first vane or the second vane and the second pattern may intersect. In this case, the angle formed by the contact point and the first vane and the second pattern, or the contact point and the second vane and the second pattern may be 30° or more, 40° or more, or 40° to 90°.

[0098] Alternatively, the second vane and the second pattern may intersect with the first vane, respectively, so that the pattern portion may include two or more contact points. At this time, the angle formed by the contact point and the first vane and the second vane and the angle formed by the contact point and the first vane and the second pattern may be 30° or more, 40° or more, or 40° to 90°.

[0099]

[0100] A method for manufacturing artificial marble according to one embodiment of the present invention comprises the steps of: forming a base layer in a plate shape by dispensing a base composition into a horizontally oriented mold; forming an intaglio pattern on the base layer using a knife for manufacturing a vein pattern of artificial marble, which will be described later; injecting a vein pattern composition into the intaglio pattern; and performing a compression process and a heat treatment process to form artificial marble having veins.

[0101] A method for manufacturing artificial marble according to one embodiment of the present invention includes a step of forming a base layer in a plate shape by spraying a base composition onto a horizontally oriented mold.

[0102] The mold may be a container having a predetermined shape so that the artificial marble composition discharged from the hopper can be contained in a predetermined shape. In particular, one embodiment of the present invention is different from the conventional process of manufacturing by vertically stacking different types of mixtures of natural quartz, unsaturated polyester liquid resin, and solid pigment, in which the mold is oriented horizontally to form a base layer in a plate shape.

[0103] The above base layer can be formed by injecting a base composition into a plurality of hoppers controlled by a digital powder dispenser and then dispensing it into a mold.

[0104] The above base composition may include a binder resin, inorganic particles, and quartz powder. The binder resin may be included in an amount of 10 wt% to 15 wt%, and preferably 10 wt% to 13.5 wt%, based on 100 wt% of the base composition. The inorganic particles may be included in an amount of 50 wt% to 60 wt%, and preferably 51 wt% to 57 wt%, based on 100 wt% of the base composition. The quartz powder may be included in an amount of 25 wt% to 40 wt%, and preferably 28 wt% to 34 wt%, based on 100 wt% of the base composition.

[0105] The above binder resin may include an unsaturated polyester (UPE) polymer and a vinyl monomer.

[0106] The above binder resin can be manufactured by mixing and dispersing 0.4 to 2.5 parts by weight of a curing agent, 0.05 to 0.3 parts by weight of a catalyst, and 0.5 to 7 parts by weight of a coupling agent with respect to 100 parts by weight of an unsaturated polyester resin, and then curing.

[0107] The unsaturated polyester resin can be manufactured using a resin mixture comprising an unsaturated polyester polymer and a vinyl monomer. Preferably, the unsaturated polyester resin is manufactured using a composition comprising an unsaturated polyester polymer and a vinyl monomer in a weight ratio of 70:30 to 30:70. More preferably, the unsaturated polyester resin is manufactured using a composition comprising an unsaturated polyester polymer and a vinyl monomer in a weight ratio of 60:40 to 40:60.

[0108] Alternatively, the unsaturated polyester resin is manufactured using a composition comprising 40 to 60 wt% of an unsaturated polyester polymer and 40 to 60 wt% of a vinyl monomer.

[0109] The above unsaturated polyester resin may be a viscous solution, typically a solution in which an unsaturated polyester polymer is diluted within the vinyl monomer. Therefore, by satisfying the content of the vinyl monomer within the aforementioned range, the viscosity can be reduced, making the unsaturated polyester resin easier to handle. Furthermore, the vinyl monomer can cure the unsaturated polyester resin from a liquid to a solid through cross-linking of polyester molecular chains without producing byproducts. The weight average molecular weight of the unsaturated polyester resin is 1,000 g / mol to 10,000 g / mol.

[0110] The above unsaturated polyester polymer is not particularly limited, and for example, an unsaturated polyester polymer produced through a condensation reaction of a saturated or unsaturated dibasic acid and a polyhydric alcohol can be used. The saturated or unsaturated dibasic acid can be ortho-phthalic acid, isophthalic acid, maleic anhydride, citraconic acid, fumaric acid, itaconic acid, phthalic acid, phthalic anhydride, terephthalic acid, succinic acid, adipic acid, sebacic acid, or tetrahydrophthalic acid. In addition, as the polyhydric alcohol, ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, polypropylene glycol, 1,3-butylene glycol, hydrogenated bisphenol A, trimethylol propane monoaryl ether, neopentyl glycol, 2,2,4-trimethyl-1,3-pentadiol and / or glycerin can be used. In addition, monobasic acids such as acrylic acid, propionic acid or benzoic acid; or polybasic acids such as trimellitic acid or benzoic tetracarboxylic acid can be further used as needed.

[0111] As the type of the above vinyl monomer, an alkyl acrylate monomer or an aromatic vinyl monomer can be used, but considering the reactivity with the unsaturated polyester polymer, it is preferable to use an aromatic vinyl monomer. For example, as the above aromatic vinyl monomer, at least one selected from the group consisting of styrene, α-methylstyrene, p-methylstyrene, vinyl toluene, alkyl styrene substituted with an alkyl group having 1 to 3 carbon atoms, and styrene substituted with a halogen can be used, and a styrene monomer can be preferably used.

[0112] The above curing agent may be included for the curing reaction of the binder, and any curing agent used in the production of engineered stone may be used without particular limitation. The curing agent may be an organic peroxide compound or an azo compound. The organic peroxide compound may be one or two or more selected from among tert-butyl peroxybenzoate thermosetting agent (TBPB, Trigonox C, Akzo Nobel), diacyl peroxide, hydroperoxide, ketone peroxide, peroxyester, peroxyketal, dialkyl peroxide, alkyl perester, percarbonate, and peroxydicarbonate. Examples thereof include, but are not limited to, tert-butyl peroxybenzoate thermosetting agent, benzoyl peroxide, dicumyl peroxide, butyl hydroperoxide, cumyl hydroperoxide, methyl ethyl ketone peroxide, t-butyl peroxy maleate, t-butyl hydroperoxide, acetyl peroxide, lauroyl peroxide, t-butyl peroxy neodecanoate, or t-amyl peroxy 2-ethyl hexanoate.

[0113] In addition, the azo compound may be azobisisobutyronitrile, but is not necessarily limited thereto. The binder resin may include 0.4 to 2.5 parts by weight of a hardener based on 100 parts by weight of the unsaturated polyester resin. If the hardener is included in an amount less than the above range, it is difficult for the binder to harden, and if it is included in an amount exceeding the above range, discoloration of the binder may occur, and thus, it may be included within the above range.

[0114] The above catalyst may be included to promote hardening of the binder at low temperatures, and may be a catalyst used in the production of engineered stone, and is not particularly limited thereto, and may be one or more selected from metal soaps such as cobalt-based, vanadium-based, or manganese-based, tertiary amines, quaternary ammonium salts, and mercaptans. For example, a cobalt 6% catalyst (Hex-Cem, Borchers) may be used. The binder resin may include 0.05 to 0.3 parts by weight of the catalyst based on 100 parts by weight of the unsaturated polyester resin. If the catalyst is included in an amount less than the above range, hardening is not promoted, and if it is included in an amount exceeding the above range, discoloration of the binder may occur, and thus, it may be included within the above range.

[0115] The coupling agent may be included to enhance the bonding strength between the binder and natural mineral particles, and may be a silane-based or silicate-based agent. The binder resin may include 0.5 to 7 parts by weight of the coupling agent relative to 100 parts by weight of the unsaturated polyester resin. If the coupling agent is included in an amount below the above range, the bonding strength with the natural mineral particles decreases, and if it is included in an amount exceeding the above range, the unit price of raw materials increases, so it may be included within the above range.

[0116] The inorganic particles of the base composition of the present invention refer to inorganic particles having a particle size of 0.1 mm to 4.0 mm. Preferably, the inorganic particles refer to inorganic particles having a particle size of 0.1 mm to 0.3 mm. The particle size can be measured using a Beckman Coulter LS 13 320 particle size analyzer.

[0117] The inorganic particles of the base composition of the present invention may be amorphous silica particles, glass particles, crystalline quartz particles, etc. In addition, the inorganic particles of the base composition may be at least one selected from the group consisting of amorphous silica particles, glass particles, and crystalline quartz particles. The inorganic particles may be amorphous silica particles or crystalline quartz particles, and in this case, the inorganic particles may be inorganic particles having a SiO2 content of 99.5 wt% to 100 wt%.

[0118] Preferably, the inorganic particles of the base composition of the present invention are amorphous silica particles, glass particles and / or crystalline quartz particles having a SiO2 content of 99.5 wt% to 100 wt%.

[0119] Artificial marble manufactured using amorphous silica particles or crystalline quartz particles having a SiO2 content of 99.5 wt% to 100 wt% as inorganic particles in a base composition has higher hardness than artificial marble manufactured using glass particles as inorganic particles. In addition, artificial marble manufactured using amorphous silica particles or crystalline quartz particles having a SiO2 content of 99.5 wt% to 100 wt% as inorganic particles in a base composition has higher hardness than artificial marble manufactured using glass particles as inorganic particles.

[0120] The inorganic particles of the above base composition may be amorphous silica particles. The silica particles are a term commonly used in the field of artificial marble, and generally refer to SiO2-based inorganic particles having a high SiO2 content of 90 wt% or more and containing a small amount of other components such as minerals in addition to SiO2. The amorphous silica particles of the base composition of the present invention may be amorphous fused silica particles, and the amorphous silica particles of the base composition may also be referred to herein as highly transparent amorphous fused silica particles. The above amorphous fused silica particles may be amorphous fused silica particles having a particle size of 0.1 mm to 4.0 mm, and further have a SiO2 content of 99.5 wt% to 100 wt%, preferably 99.6 wt% to 100 wt%, more preferably 99.7 wt% to 100 wt%, and an alumina content of 0.5 wt% or less, preferably 0.4 wt% or less, more preferably 0.3 wt% or less, and still more preferably 0.2 wt% or less. When the SiO2 content in the amorphous silica particles is 99.5 wt% or more, preferably 99.6 wt% or more, and more preferably 99.7 wt% or more, the transparency of the base layer of the artificial marble is further improved.

[0121] The SiO2 content of the silica particles and quartz particles of the present invention can be confirmed by quantitative analysis of the content using an XRF (X-Ray Fluorescence spectrometer). In addition, crystalline particles and amorphous particles can be confirmed using XRD (X-ray diffraction), and can generally be confirmed by measuring the particles after making them into pellets.

[0122] The inorganic particles of the base composition of the present invention may be crystalline quartz particles. The crystalline quartz particles of the base portion of the present invention may also be referred to herein as highly transparent crystalline quartz particles.

[0123] At this time, the crystalline quartz particles of the base portion may be highly transparent crystalline quartz particles having a particle size of 0.1 mm to 4.0 mm, and may also have a SiO2 content of 99.5 wt% to 100 wt%, preferably 99.6 wt% to 100 wt%, more preferably 99.7 wt% to 100 wt%, and an alumina content of 0.5 wt% or less, preferably 0.4 wt% or less, more preferably 0.3 wt% or less, and even more preferably 0.2 wt% or less.

[0124] If the SiO2 content in the crystalline quartz particles of the above base composition is less than 99.5 wt%, for example, 99.4 wt% or less, the transparency of the artificial marble decreases. Therefore, it is preferable that the crystalline quartz particles have a SiO2 content of 99.5 wt% or more.

[0125] In the present invention, quartz powder refers to quartz powder having a particle size of 0.1 mm or less. The particle size can be measured using a Beckman Coulter LS 13 320 particle size analyzer.

[0126] The quartz powder of the base composition of the present invention may also be referred to herein as a high-transparency crystalline quartz powder.

[0127] The quartz powder of the base composition of the present invention is a crystalline quartz powder, and is preferably a crystalline quartz powder having a SiO2 content of 99.5 wt% to 100 wt%. The quartz powder of the base composition may have a SiO2 content of 99.5 wt% to 100 wt%, preferably 99.6 wt% to 100 wt%, more preferably 99.7 wt% to 100 wt%, and an alumina content of 0.5 wt% or less, preferably 0.4 wt% or less, more preferably 0.3 wt% or less, and even more preferably 0.2 wt% or less.

[0128] The quartz powder of the above base composition preferably has an average SiO2 content of 99.5 wt% to 100 wt%, and an average alumina content of 0.5 wt% or less.

[0129] The SiO2 content of the quartz powder of the above base composition can be confirmed by quantitative analysis of the content using an XRF (X-Ray Fluorescence spectrometer). In this case, the content can generally be confirmed by making the powders into pellets and then measuring them.

[0130] Since the quartz powder of the above base composition has small particle size, self-scattering occurs. Therefore, in order to increase the internal transmittance of the base layer of the artificial marble, the base composition of the present invention may use crystalline quartz powder having a SiO2 content of 99.5 wt% or more. If the SiO2 content of the quartz powder is less than 99.5 wt%, the internal transmittance of the base portion of the artificial marble is low, so that an artificial marble having a relatively low transparency of the base layer can be manufactured.

[0131] The above base composition may include 500 to 700 parts by weight of inorganic particles and 200 to 400 parts by weight of quartz powder per 100 parts by weight of binder resin.

[0132] In addition, the base composition includes 500 to 700 parts by weight of inorganic particles and 200 to 400 parts by weight of quartz powder with respect to 100 parts by weight of binder resin, the binder resin includes an unsaturated polyester polymer and a styrene monomer at a ratio of 70:30 to 30:70, and the quartz powder may have a SiO2 content of 99.5 to 100 wt% and an alumina content of 0.5 wt% or less.

[0133] In one embodiment of the present invention, the step of forming a base layer in a plate shape by spraying a base composition onto a horizontally oriented mold may additionally include a compaction process of the base layer. The compaction process is a step of primarily pressing the sprayed base composition, and can serve to create a certain gap to prevent the compound from collapsing or breaking during the subsequent step of forming an intaglio pattern. In particular, in order to form a vein having a thickness of 3 mm to 5 mm, it is preferable to perform the compaction process.

[0134] A method for manufacturing artificial marble according to one embodiment of the present invention includes a step of forming an engraved pattern on the base layer. The step of forming the engraved pattern on the base layer is characterized by using a knife for manufacturing a vein pattern of artificial marble according to the present invention. Specifically, the step of forming the engraved pattern according to the present invention forms the engraved pattern on the base layer at once using a knife for manufacturing a vein pattern of artificial marble.

[0135] At this time, if the knife includes one embossing plate, multiple knives with different widths can be used to form veins with different sharpness on one artificial marble.

[0136] For example, a 40mm wide knife and a 10mm wide knife can be used to form an intaglio pattern with a width of 40mm and an intaglio pattern with a width of 10mm on the base layer, respectively.

[0137] Alternatively, the width of the engraved pattern may increase or decrease in one direction. In other words, the engraved pattern may become narrower in one direction.

[0138] The width of the engraved pattern may be 10 mm to 80 mm. Alternatively, the difference between the widest and narrowest portions of the engraved pattern may be 30 mm or more. Alternatively, the width of the engraved pattern may be 10 mm to 80 mm, and the difference between the widest and narrowest portions of the engraved pattern may be 10 mm or more. Preferably, the difference in width may be 20 mm or more, and more preferably, it may be 30 mm or more.

[0139] If the width of the intaglio pattern is less than 10 mm, the area in which the vein composition can be distributed in the intaglio pattern is narrow, so veins may not appear on the surface of the artificial marble after the compression process and heat treatment process described below.

[0140] If the width of the engraved pattern exceeds 80 mm, the engraved pattern may be formed excessively wide, and the vein may not be covered by the base layer during the compression process. In other words, this is not desirable because cracks or pinholes may occur.

[0141] And, the depth of the engraved pattern may be 80% or less of the thickness of the base layer, 75% or less, or 50% or more.

[0142] Furthermore, the engraved pattern may include two or more patterns having different depths. Accordingly, the engraved pattern may be formed in a W or gear shape including a plurality of convex and concave portions based on a vertical cross-section, and the heights of the convex portions may be different.

[0143] For example, if the engraved pattern includes three convex portions, the heights of the convex portions can be formed in the order of 80%, 50%, and 80% of the thickness of the base layer, and the sharpness of the vein can be adjusted according to the height difference of the engraved portion pattern.

[0144] If the depth of the engraved pattern exceeds 80% of the thickness of the base layer, the knife for manufacturing the vein may touch the lower floor during the process of forming the engraved pattern on the base layer, and the area of ​​the vein may become excessively large, making it difficult to completely dry the vein. In addition, if the depth of the engraved pattern is less than 50% of the thickness of the base layer, the vein may be removed during post-processing such as banding or cutting down of the manufactured artificial marble, which is not preferable.

[0145] The above engraved pattern can be formed in a form in which multiple engraved patterns intersect.

[0146] The depth of the above-mentioned engraved pattern may be 80% or less of the thickness of the base layer, 75% or less, or 50% or more.

[0147] If the depth of the engraved pattern exceeds 80% of the thickness of the base layer, the knife for manufacturing the vein may touch the lower floor during the process of forming the engraved pattern on the base layer, and the area of ​​the vein may become excessively large, making it difficult to completely dry the vein. In addition, if the depth of the engraved pattern is less than 50% of the thickness of the base layer, the vein may be removed during post-processing such as banding or cutting down of the manufactured artificial marble, which is not preferable.

[0148] A method for manufacturing artificial marble according to one embodiment of the present invention includes a step of injecting a vein pattern composition into the engraved pattern.

[0149] The above-mentioned vein composition may include a binder resin and a pigment. In addition, the vein composition may further include inorganic particles, quartz powder, and a monomer. For example, the monomer may be a styrene monomer.

[0150] The inorganic particles and quartz powder that may be further included in the above-mentioned vein composition may be applied to the contents of the inorganic particles and quartz powder of the above-mentioned base composition, so a detailed description thereof will be omitted.

[0151] The binder resin may be included in an amount of 85 wt% to 99 wt%, preferably 90 wt% to 99 wt%, based on 100 wt% of the vein composition. The pigment may be included in an amount of 1 wt% to 15 wt%, preferably 1 wt% to 10 wt%, based on 100 wt% of the vein composition.

[0152] The above pigment is preferably an inorganic pigment. The pigment may be any pigment commonly used in the production of artificial marble and is not particularly limited. For example, it may be TiO2, NiO·Sb2O3·20TiO2, Fe2O3, Fe3O4, etc.

[0153] At this time, in order to manufacture veins having various color differences, multiple vein compositions having pigments capable of expressing each color difference applied can be used.

[0154] The mixing of the above-mentioned vein composition can be performed by a dry mixer or a wet mixer applied in a ceramic powder mixing process.

[0155] The brightness value (L), saturation value (C) and color difference (△E) according to the present invention are values ​​measured for the first and second veins or two or more consecutive regions of artificial marble manufactured using a vein pattern composition of the same color and a vein pattern composition of the same concentration.

[0156] In other words, according to the present invention, the difference in brightness value, the ratio of brightness value, the ratio of saturation value, and the difference in color difference can be produced by manufacturing a vein pattern composition including the same color pigment in the same weight %, and then injecting the vein pattern composition into the intaglio pattern to manufacture an artificial marble including a first pattern including a first vein and a second vein or a second pattern including two or more consecutive regions.

[0157] In one embodiment of the present invention, the step of injecting the vein composition into the engraved pattern may be performed by a powdering process or a spraying process of discharging the vein composition. By this process, the veins of the artificial marble can be implemented in the form of various color differences, and not only can thin and clear veins having one or more color differences be formed adjacent to each other, but also can implement a natural flowing pattern, a spreading pattern, etc., such as a gradation color difference. Accordingly, the vein according to one embodiment of the present invention may have two or more color differences, a gradation color difference, or a color difference of a combination thereof. In addition, the vein according to one embodiment of the present invention may include a straight line pattern, a curved pattern, or a combination pattern thereof.

[0158] In one embodiment of the present invention, after the step of injecting a vein pattern composition into the engraved pattern, a step of performing a compression process and a heat treatment process to form an artificial marble having a vein is included.

[0159] The above compression process and heat treatment process can utilize methods known in the art. For example, the above compression process can be performed in a range of 20,000 tons or more based on the production of slabs measuring 3,000 mm Х 1,400 mm, but is not limited thereto.

[0160] In one embodiment, the compression process may use a roll to compress the base layer and the vein composition to disperse the engraved pattern portion. At this time, the diameter or height of the roll may be 50 mm or greater.

[0161] As the diameter of the roll satisfies the above range, the pressure with which the roll presses the base layer and the negative pattern portion is reduced, so that the vein composition penetrates into the periphery of the negative pattern portion, and the vein can be implemented in a natural shape including multiple branches.

[0162] The above heat treatment process may be applied at various temperatures depending on the type of binder resin, but is preferably performed at 90°C to 250°C. In addition, the above heat treatment process may be applied at various times depending on the type and size of the polymer resin, but is preferably performed for 5 to 60 minutes.

[0163] After the above compression process and heat treatment process, a process of removing the mold, a post-processing process of cutting all sides of the artificial marble and then polishing the surface to make it smooth, etc. may be additionally sequentially included.

[0164]

[0165] The knife (1) for manufacturing the vein of the above artificial marble includes at least one embossing plate (100).

[0166] The embossing plate (100) includes a first inclined surface (110) and a second inclined surface (120), and the first inclined surface (110) and the second inclined surface (120) can be positioned to face each other based on the moving direction of the knife (1). At this time, the moving direction of the knife (1) means the direction of gravity, i.e., the direction perpendicular to the upper surface of the mold including the ground or base layer.

[0167] Accordingly, the first inclined surface (110) and the second inclined surface (120) can form a certain angle (θ) with an imaginary line that is horizontal to the direction of movement of the knife (1). The angle (θ) can be 0° to 80°. Preferably, it can be 0° to 70°.

[0168] The emboss plate (100) increases in width (W) from one side to the other. The width of the emboss plate (100) refers to the distance between the first inclined surface (110) and the second inclined surface (120). Therefore, the distance between the first inclined surface (110) and the second inclined surface may increase from one end of the emboss plate (100) to the other end. In this case, one end of the emboss plate (100) refers to the side adjacent to the ground or mold, and the other end refers to the opposite side of the one end.

[0169] If the width of the emboss plate (100) increases, the angles (θ1, θ2) formed by each of the first inclined surface (110) and the second inclined surface (120) with the above-described virtual line are not limited.

[0170] In other words, the first angle (θ1) formed by the first inclined plane (110) and the imaginary line and the second angle (θ2) formed by the second inclined plane (120) and the imaginary line may be the same or different. For example, the first angle and the second angle may both be 40°. Alternatively, the first angle may be 0° and the second angle may be 50°.

[0171] When the knife (1) includes one emboss plate (100), the knife (1) may have the same width along the longitudinal direction. In other words, since the shape of the knife (1) is determined by one emboss plate (100), the knife (1) has the same width and length as the emboss plate (100). Therefore, the knife (1) may be formed with a constant width and length.

[0172] Alternatively, two or more of the emboss plates (100) included in the knife (1) may have different widths. In other words, the knife (1) may include two or more emboss plates (100) having different widths. That is, when the knife (1) includes two or more emboss plates (100), the knife (1) may include two or more emboss plates (100) having different widths.

[0173] The plurality of emboss plates (100) may each have different widths. That is, among the plurality of emboss plates (100) included in the knife (1) according to the present invention, at least one emboss plate (100) may have different widths. In other words, the knife (1) may have at least two or more emboss plates (100) that all have different widths, or have the same width.

[0174] At this time, the width of the emboss plate (100) is based on the widest distance between the first inclined surface (110) and the second inclined surface (120).

[0175] The knife (1) may have a plurality of emboss plates (100) arranged in one or more directions, either the length direction (L) or the width direction (W) of the knife (1).

[0176] Referring to FIGS. 2 to 6, the knife (1) may have a plurality of emboss plates (100) having different widths arranged along the length direction of the knife (1).

[0177] The knife (1) of FIGS. 2 and 3 has two emboss plates (100a, 100b) of different widths arranged along the longitudinal direction of the knife (1), and the knife (1) of FIG. 3 has three emboss plates (100a, 100b, 100c) of different widths arranged along the longitudinal direction of the knife (1).

[0178] And, the emboss plates (100a, 100b, 100c) of the knife (1) according to FIGS. 2 to 4 can be arranged so that the width of the emboss plates (100a, 100b, 100c) gradually increases or decreases along the longitudinal direction of the knife (1).

[0179] Accordingly, the vein formed by the knife (1) can be gradient-shaped with the color of the vein darkening or decreasing in one direction.

[0180] Alternatively, referring to FIGS. 5 and 6, the knife (1) includes three emboss plates (100a, 100b, 100c), and the emboss plates (100a, 100b, 100c) may not be arranged so that their widths gradually increase or decrease in the longitudinal direction of the knife (1).

[0181] In detail, the knife (1) of FIG. 5 includes three emboss plates (100a, 100b), two emboss plates (100a) having the same width and one emboss plate (100b) having a different width.

[0182] The knife (1) of Fig. 6 includes three emboss plates (100a, 100b, 100c) all having different widths.

[0183] By not regularly arranging embossed plates (100) of different widths, a single vein can include a variety of sharpnesses, providing a uniquely designed artificial marble. Furthermore, by forming the veins with non-uniform sharpnesses, the unique texture of a material, such as natural stone, can be realized in a variety of ways.

[0184] The maximum width of the emboss plate (100) may be 10 mm to 80 mm. Preferably, it may be 10 mm to 60 mm, and more preferably, it may be 10 mm to 40 mm.

[0185] And, among two or more emboss plates (100) included in one knife (1), the width difference between the widest emboss plate (100) and the narrowest emboss plate (100) may be 10 mm or more. Preferably, the width difference may be 20 mm or more, and more preferably, 30 mm.

[0186] According to one embodiment, the knife (1) may have a plurality of emboss plates (100) provided on the knife (1) such that the widths thereof satisfy both of the above conditions. For example, the knife (1) may include two emboss plates (100), and the width of the widest emboss plate (100) may be 40 mm, and the width of the narrowest emboss plate (100) may be 10 mm.

[0187] Alternatively, the knife (1) according to another embodiment may have a width of an emboss plate (100) provided on the knife (1) that satisfies only one of the two conditions above.

[0188] For example, the knife (1) may include two emboss plates (100), the width of the widest emboss plate (100) may be 30 mm, and the width of the narrowest emboss plate (100) may be 10 mm.

[0189] Alternatively, the knife (1) may include two emboss plates (100), the width of the widest emboss plate (100) may be 60 mm, and the width of the narrowest emboss plate (100) may be 30 mm.

[0190] When the difference in width between the widest emboss plate (100) and the narrowest emboss plate (100) satisfies the above range, the difference in sharpness of the veins is clearly shown, which can provide a contrast between dark and light lines.

[0191] Fig. 8 is a photograph illustrating the shape of a knife having an emboss plate intersected according to the present invention. The knife (1) may be provided in various shapes, such as a straight line, a curved line, a combination thereof, a Y shape, an X shape, a zigzag shape, etc. in which multiple knives (1) intersect.

[0192] When a plurality of knives (1) are provided and the plurality of knives (1) intersect, the intersection angle (α) between the two knives (1) may be 40° to 90°. Preferably, the intersection angle (α) may be 40° to 70°.

[0193] When the intersection angle (α) of the knives (1) satisfies the above range, the base layer can be prevented from remaining between multiple knives (1). If the base layer remains between the knives (1), problems may arise when washing the knives (1) during multiple uses or when the shape of the blade becomes unclear thereafter.

[0194] According to another embodiment of the invention, a knife (1) according to FIG. 7 may include two or more emboss plates (100) having a pair of inclined surfaces in the width direction of the knife (1), and at least two of the plurality of emboss plates (100) may have the same width, or all of the plurality of emboss plates (100) may have different widths.

[0195] For example, a knife (1) may be arranged such that an emboss plate (100a) having a width of 40 mm, an emboss plate (100b) having a width of 20 mm, and an emboss plate (100a) having a width of 40 mm are provided. The angle formed by the first inclined surface (110a) and the second inclined surface (120a) of the emboss plate (100a) having a width of 40 mm may be greater than the angle formed by the first inclined surface (110b) and the second inclined surface (120b) of the emboss plate (100b) having a width of 20 mm.

[0196] Alternatively, a plurality of emboss plates (100) having different widths may be arranged so as to gradually increase or decrease in the width direction. Alternatively, a plurality of emboss plates (100) having different widths may be arranged irregularly along the width direction.

[0197] By positioning two or more veins of different clarity adjacent to one artificial marble, a design similar to natural marble can be provided.

[0198]

[0199] And, according to another embodiment, the knife (1) may include a plurality of emboss plates (100) having different widths in the longitudinal and width directions of the knife (1). That is, the knife (1) according to another embodiment may be a combination of the knife (1) according to one embodiment and the knife (1) according to another embodiment.

[0200]

[0201] Although the present invention has been described above with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various modifications and changes may be made to the present invention without departing from the spirit and scope of the present invention as set forth in the claims below.

[0202]

[0203] Materials and Methods

[0204] A base composition is sprayed onto a mold and pressed with a roller to smooth the surface of the base composition, thereby producing a base layer. Then, a vein pattern-making knife is used to form an engraved pattern on the smoothed base layer. A vein pattern composition with a color difference is sprayed onto the engraved pattern using a spray-type device, followed by compression and heat treatment to produce artificial marble.

[0205] The base composition includes a binder resin, inorganic particles, and quartz powder. Unsaturated polyester was used as the binder resin, and quartz particles having a particle size of 0.1 to 0.3 mm were used as the inorganic particles.

[0206] The quartz powder used was a highly transparent crystalline quartz powder having a particle size of 0.044 mm or less. In addition, the crystalline quartz powder has an alumina content of 0.5 wt% or less. At this time, the crystalline quartz powder used had a SiO2 content of 99.7 wt% or more and 100 wt% or less, and an average SiO2 content of 99.7 wt%.

[0207] The method for manufacturing the above base composition is as follows: 53.0 wt% of inorganic particles having a particle size of 0.1 to 0.3 mm are mixed with 1.7 wt% of an inorganic pigment of white color, TiO2. Then, the inorganic particles and the inorganic pigment are mixed at 10 rpm for 1 minute using a mixer equipped with a ceramic rod, and then 12.4 wt% of a binder resin is added and mixed at 5 rpm for 1 minute.

[0208] Afterwards, add 32.9 wt% quartz powder to the mixer and mix at 10 rpm for 1 minute.

[0209] The above composition, in which binder resin, inorganic particles, quartz powder, and inorganic pigment are mixed in a mixer, is further mixed at 10 rpm for 1 minute.

[0210] Afterwards, the base composition is evenly distributed onto the prepared rubber mold. At this time, a release paper or film is attached to the rubber mold before dispensing the composition.

[0211] The vein pattern composition may include a binder resin and a pigment. The pigment is an inorganic pigment, and the inorganic pigment used in the production of artificial marble, such as TiO2, NiO·Sb2O3·20TiO2, Fe2O3, and Fe3O4, was purchased and used.

[0212] The vein pattern composition was prepared by mixing 4.0 wt% of an inorganic pigment with 96.0 wt% of a binder resin to form a mixture of an inorganic pigment and a binder resin. The mixture was first stirred at 200 rpm for 30 minutes using a stirrer to ensure that the inorganic pigment was well dispersed in the binder resin.

[0213] Afterwards, a mixture of binder resin and inorganic pigment is diluted by mixing 3 to 10 wt% of styrene monomer according to the viscosity so that the value measured after 1 min at 30 rpm at 25°C using a Brookfield viscometer (Model: DV1MLV) is between 60 and 80 cPs, and a vein pattern composition is prepared.

[0214] The above-mentioned manufactured vein pattern composition was applied at 4 g / mm onto the engraved pattern using a sprayer attached to a robot arm, and then compression molded using a vacuum pressurization device. Then, it was cured at 120°C for 40 minutes, and after curing was complete, it was removed from the mold and cooled to room temperature to manufacture a semi-finished artificial marble product. After cutting all four sides of the artificial marble, the surface was polished smoothly to manufacture an artificial marble sample.

[0215] <Example 1>

[0216] Using a knife for manufacturing a vein pattern including a first emboss plate having a width of 40 mm and a second emboss plate having a width of 10 mm, a first vein and a second vein having a negative pattern and a width of 40 mm and 10 mm, respectively, are formed on a mold including a base composition.

[0217] A knife for manufacturing a vein pattern includes a single contact point where a first emboss plate and a second emboss plate meet, and is also provided in a Y shape. The knife is provided such that the angle formed by the contact point and the first emboss plate and the second emboss plate is 40°, and the second emboss plate extends from the first emboss plate.

[0218] Pigments include gold pigment.

[0219] Five random points were selected from each of the first and second vanes, and the L, a, b, and E values ​​according to CIE were measured. The average value of the L, a, b, and E values ​​of three points excluding the highest and lowest values ​​was calculated.

[0220] <Example 2>

[0221] An artificial marble was manufactured under the same conditions as Example 1, except that the knife for manufacturing a vein pattern was provided in a form in which the end of the first emboss plate and the end of the second emboss plate were connected continuously, the width of the first emboss plate was 30 mm, and gray pigment was included as the pigment.

[0222] <Comparative Example 1>

[0223] Artificial marble was manufactured under the same conditions as Example 1, except that the knife for manufacturing the vein pattern included only one embossing plate with a width of 40 mm.

[0224] Comparative Example 2

[0225] Artificial marble was manufactured under the same conditions as Example 2, except that the knife for manufacturing the vein pattern included only one embossing plate with a width of 30 mm.

[0226] Color width△E(E max- E min )△L(L max -L min )△L(L min / L max )△C(C min / C max )Example 1Gold40㎜ / 10㎜16.649.20.90.33Example 2Gray30㎜ / 10㎜9.079.001.110.49Comparative Example 1Gold40㎜0.940.700.990.87Comparative Example 2Gray30㎜2.652.40.970.75

[0227] Comparative Examples 1 and 2 are formed by embossing plates in which a continuous pattern has the same width, and the difference in brightness and saturation values ​​is not large. Therefore, it can be seen that Comparative Examples 1 and 2 have a difference in brightness of less than 3, and a ratio of brightness and saturation values ​​close to 1.

[0228] Also, the color difference (△E) determined by the brightness and saturation values ​​is less than 3, so the human eye cannot recognize the color difference in the parts where the brightness and saturation values ​​are different.

[0229] Examples 1 and 2 have large differences in brightness and saturation depending on the difference in the width of the engraved pattern of the first and second vanes. Therefore, it can be seen that Examples 1 and 2 have a difference in brightness of 9 or more, and a ratio of brightness and saturation of less than 1.

[0230] In addition, the color difference determined by the brightness value and saturation value is 9 or more, so that the difference in brightness value and saturation value between the first and second vanes can be recognized by both expert and general human eyes.

Claims

1. Includes base and pattern parts, The above pattern portion includes at least one of a first pattern and a second pattern, The above first pattern includes a first vane and a second vane having a difference in brightness value (L) calculated using CIE color coordinate values ​​of 4 or more, An artificial marble, wherein the second pattern includes a vein comprising two or more consecutive portions, and the difference in brightness value (L) calculated using CIE color coordinate values ​​of the two or more consecutive portions is 4 or more.

2. An artificial marble in the first paragraph, wherein the brightness value ratio between the first and second vanes is 0.95 or less, or the brightness value ratio of two or more consecutive portions is 0.95 or less.

3. An artificial marble according to claim 1, wherein the first pattern includes the first vein and the second vein having a saturation value (C) ratio calculated using CIE color coordinates of less than 0.7, or the second pattern includes two or more consecutive portions having a saturation value (C) ratio calculated using CIE color coordinates of less than 0.

7.

4. An artificial marble in the first paragraph, wherein the first pattern includes the first vein and the second vein having a color difference (△E) exceeding 3 calculated with a CIE color coordinate value, or the second pattern includes two or more consecutive portions having a color difference (△E) exceeding 3 calculated with a CIE color coordinate value.

5. An artificial marble in the first paragraph, wherein the boundary between two or more consecutive parts is gradient.

6. An artificial marble according to claim 1, wherein the first pattern and the second pattern each independently include two or more veins having a total length of 5 cm or more.

7. In the first paragraph, the first pattern includes at least one contact point where the first vane and the second vane intersect each other, or An artificial marble wherein the pattern portion includes a plurality of second patterns, and the plurality of second patterns intersect with each other and include at least one contact point.

8. In the 7th paragraph, the angle formed by the first pattern, the first vane, and the second vane is 30° or more, The above second pattern is an artificial marble in which the angle formed by the above contact point and the two second patterns is 30° or greater.

9. In the first paragraph, the second pattern is included in multiple numbers, and the minimum distance between two adjacent patterns among the multiple second patterns is less than 80 mm, or An artificial marble wherein the minimum distance between the first vane and the second vane is less than 80 mm.

10. In the knife for making vein patterns, It includes an embossing plate having a first inclined surface and a second inclined surface which are opposite to each other based on the direction of movement of the knife, The above knife comprises at least two of the above embossing plates, A knife for manufacturing a vein pattern, wherein at least two of the above embossing plates have different widths, and the width of the embossing plates is the maximum distance between the first inclined surface and the second inclined surface.

11. In the 10th paragraph, the embossing plate is arranged in at least one direction among the length direction and width direction of the knife, The width of the above embossed plate is 10mm to 80mm, The above knife is a knife for manufacturing a vein pattern, wherein the difference in width between the narrowest emboss plate and the widest emboss plate is 10mm or more.

12. In the 10th paragraph, the knife is included in multiple numbers, A knife for manufacturing a vein pattern, wherein a plurality of knives intersect each other at an angle of 40° to 90°.

13. A base layer forming step of forming a base layer in a plate shape by spraying a base composition onto a horizontally oriented mold; A pattern forming step of forming an engraved pattern on the base layer using a knife for manufacturing a vein pattern of the first clause; A vein injection step of injecting a vein pattern composition into the above-mentioned negative pattern; and An artificial marble forming step in which an artificial marble having a vein pattern is formed by performing a compression process and a heat treatment process. A method for manufacturing artificial marble comprising:

14. In the 13th paragraph, in the pattern forming step, the engraved pattern becomes narrower in one direction, A method for manufacturing artificial marble, wherein in the above pattern forming step, a plurality of engraved patterns are formed in a shape in which they intersect each other.

15. Artificial marble manufactured by the method for manufacturing artificial marble in Article 13.

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